Keep pulling! It doesnt lift out, rather up until it hits the housing on the chassis, thrn pulks fkrward.

If the metal belt guide pin has come adrift, it could be a right bastard. The pin is easily bent straight again if it becomes bent though.

Plan B is to take the whole brusbroll off and wriggle the bent off the motor, then lift the cover off.

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Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

Thank you, beko1987. It sounds like we’re not the only ones who have struggled with a clutch cover. We worked on removing the clutch cover and…I have good news and possibly not great news.

The good news: the clutch cover is off. Thinking that the very stretched and loose belt might be hampering removal of the cover, we cut that and after brief resistance, it came loose. That did seem to help with moving the cover. We pulled up, there was a snap (sigh), and then the cover came off.

Backtrack a little. We had had a terrible time unscrewing the 3rd screw, but finally managed to shake it loose. Which brings me to the not great news: there was a 4th screw (now that’s a right bastard)! The snap was the sound of the plastic screw-post, well, breaking. How is it possible that there were 4 screws? One screw drilled down into another? We’ve never had the vacuum open before. Feeling silly that I didn’t check for something like that.

Current plan A and I’m open to suggestions/warnings here. We’re going to try gluing the post together, maybe use a slightly longer screw if there’s room and fingers crossed that it doesn’t shake loose during operation. My project right now is to find out what kind of plastic forms the body of the machine. Does anyone know?

If you need to glue the post back in, line it up dry first & make an alignment mark. Use plumbers pipe weld to glue the 2 pieces together (better than super glue) & align the marks. Once it's fully cured, you could use plastic putty to strengthen the post.When refitting the screw, make sure you don't over tighten it. Never had 1 where the screws have shaken loose.

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Repairs to All makes of Small Commercial & Domestic appliance. Power tool repair.City & Guilds and PAT qualified engineer.

Glad you got it off. Someone must have been there before though, as there's only 3 screws. Hopefully it's not chewed up the thread on the hole too much. You may get away with a slightly wider screw to sort this (then confuse the next refurbisher who opens it up when one screw isnt a torx!)

You could glue it up, qbond works well for dysons I find, but the cover itself is so cheap, mvacs or someone else on here (I have no spares I'm afraid) should be able to send you one for a beer and postage.

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Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

We finally finished up last weekend. The broken post was glued successfully and held, clutch installed, belts stretched (yikes!), and the rest of the parts reassembled, ready for the moment of truth–works like a charm.

I kept the mysterious 4th clutch cover screw as a kind of token, a reminder to stop, think, retrace steps if necessary, when something is stubbornly “illogical”.

We would not have had the confidence to continue without advice from this forum.

Excellent, well done on a satisfying outcome! Once youve done it its not as scary is it!

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Collector and restorer of vintage vacuums, Dyson Appreciator! Come and see my blog, where I am uploading all my mountains of brochures, manuals and other vacuum cleaner paperwork, and also my youtube channel @beko1987!

There are 4 screws to remove - or at least 3 correct ones. The hidden one is the problem child. If you do not rotate the head to the correct position, you can remove the wrong 3rd screw. I did. Cover would not come off. Broke it. Then I saw that the rear screw was not removed even though I had removed 3 already. This could be your problem. Once it was off, the cover should come off relatively easily.